Fusion undergarment

ABSTRACT

A fusion undergarment, and more particularly a brassiere, having a transparent layer with an inner surface and an outer surface, a support layer having an inner surface and an outer surface, and an adhesive layer for fusing the transparent layer with the support layer. The undergarment provides a balance of comfort, support and sensual appeal. The fusing process comprising the steps of fusing the adhesive layer to the support layer, cutting the fused adhesive-support layer into a desired shape, fusing the cut adhesive-support layer to the transparent layer, forming the breast supporting cup portions of the bra, preferably in a subsequent molding action. When the bra is worn, the support layer extends primarily under a wearer&#39;s breasts along a lower and side breast profile providing an optimal balance of comfort and support, while the transparent layer provides the requisite sensual appeal.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates to women's undergarments. Moreparticularly, the present invention relates to brassieres.

[0003] 2. Description of the Related Art

[0004] Conventional brassieres have a pair of breast cups, which providesupport for the breasts, and preferably one or more straps for fasteningover the shoulders and around the thorax to keep the breasts in place.The manufacturers of brassieres are constantly challenged to developbrassieres that provide optimal comfort, effective support, as well as asensual appeal and feminine allure. Traditionally, brassieres have beenmade using cut pieces of fabric that are sewn together, particularly inthe zones intended to form a three-dimensional capacity such as thebreast supporting cup portions of the brassieres. Over the years,manufacturers, in an effort to meet the above noted challenges, havedeveloped brassieres that improve wearing comfort through bondingtechniques that reduce and even eliminate the need for stitched seams,support through inserts and/or support pads that cooperate with thebreast supporting cups to reduce breast mastoptosis and deformationcaused by gravity, and that improve feminine allure through the use ofmore soft, sheer and even transparent fabrics.

[0005] It is often the situation that undergarments, and moreparticularly brassieres, when designed for improved comfort and support,substantially lack sensual appeal. The opposite being true when emphasisis placed on sensual appeal rather than comfort and support. Thus, thereremains a need for providing an undergarment, and more specifically abrassiere or bra, that offers an optimal balance of comfort, support andsensual appeal.

SUMMARY OF THE INVENTION

[0006] It is an object of the present invention to provide anundergarment that meets the above identified need for providing theoptimal balance of comfort, support and sensual appeal.

[0007] It is another object of the present invention to provide anundergarment that offers improved durability and longevity.

[0008] These and other objects and advantages of the present inventionare achieved by an undergarment, and more particularly a bra, having atransparent layer with an inner and outer surface, a support layer alsohaving an inner and outer surface, and an adhesive layer for fusing theinner surface of the transparent layer with the outer surface of thesupport layer. The fusing process has the steps of first, fusing theadhesive layer to a surface of the support layer, then, cutting thefused adhesive-support layer into a desired shape, followed by, fusingthe cut adhesive-support layer to the inner surface of the transparentlayer, and finally, in a subsequent molding action, forming the breastsupporting cup portions of the bra such that when the bra is worn, thesupport layer extends primarily under a wearer's breasts along the lowerand side breast profile. The support layer provides an optimal balanceof comfort and support, while the transparent layer provides therequisite sensual appeal.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Other and further objects, advantages and features of the presentinvention will be understood by reference to the following specificationin conjunction with the accompanying drawings, in which like referencecharacters denote like elements of structure.

[0010]FIG. 1 is a front view of a brassiere in accordance with anillustrative embodiment of the present invention;

[0011]FIG. 2 is an exploded perspective view of the brassiere of FIG. 1;

[0012]FIG. 3 is an enlarged cross-sectional view illustrating a firstforming step in accordance with the present invention;

[0013]FIG. 4 is an enlarged cross-sectional view illustrating a secondforming step in accordance with the present invention;

[0014]FIG. 5 is a cross-sectional view illustrating a third forming stepin accordance with the present invention; and

[0015]FIG. 6 is a cross-sectional view illustrating a molding step inaccordance with the illustrative embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to the drawings and, in particular, to FIGS. 1 and 2,there is shown an illustrative embodiment of an improved undergarment,for example a brassiere, generally represented by reference numeral 10.The brassiere 10 essentially has a transparent inner layer 20, an outer,support layer 30, and an adhesive layer 40, shown in FIG. 4, for fusinga surface of the transparent layer with a surface of the support layer.The brassiere 10 also has a pair of cups 50, preferably a pair ofshoulder straps 55 associated with each respective cup, and preferably apair of back straps 60 being selectively secured via a fastener 65 atthe back of a wearer. Preferably shoulder straps 55 extend from an upperpart of each respective cup 50 over the wearer's respective shouldersand are connected to the back of the brassiere 10.

[0017] The transparent layer 20 is preferably a thin piece of materialmade of either natural or man-made fiber, or a combination of both.Transparent layer 20 is preferably lightweight and has a sheer,shimmering characteristic, such as that provided by chiffon, georgette,voile, illusion, organza, or tulle. It is also preferable that man-madefibers having at least a moderate degree of elasticity, flexibility andresiliency, may be incorporated into the transparent layer. Thetransparent layer 20.may also take the form of a mesh of syntheticblends and/or form a variety of attractive patterns and providingimproved comfort and flexibility. Most preferably, transparent layer 20is a nylon/lycra mix. The transparent layer 20 can preferably be shapedinto any desirable form sufficient to accommodate the breasts of awearer and create a more sensual appeal and feminine allure thereto. Thetransparent layer 20 has an inner surface 22 and an outer surface 24shown in FIG. 5.

[0018] The support layer 30 preferably takes the form of at least onepiece of material made of either natural or man-made fiber, or acombination of both. The support layer 30 is at least somewhat lessflexible than transparent layer 20. The support layer 30 can be formedfrom any material suitable for improving the comfort and supportprovided to the breasts of a wearer. Preferably, support layer 30 is anylon/lycra mix. The support layer 30 can preferably be shaped and sizedto conform comfortably against the breasts of a wearer and to providesupport and/or augmentation thereto. Preferably, support layer 30 issecured only where essential for breast support. As shown in FIG. 4,support layer 30 has an inner surface 32 and an outer surface 34. Inanother embodiment, the support layer 30 can be transparent.

[0019] The adhesive layer 40 is preferably a thermoadhesive materialthat is sufficient for use with a variety of different types of fibers,films and materials, including those materials identified above for usewith transparent layer 20 and support layer 30. The adhesive layer 40preferably has elastic properties sufficient to compliment thoseproperties associated with the fibers or materials used in transparentlayer 20 and/or support layer 30. It is noted that adhesive layer 40 ispreferably suitable for use with a variety of fibers and fabric formingtechniques, including microfibers and specialized nonwovens. The preciseselection and matching of adhesive layer 40 to transparent layer 20 aswell as support layer 30, is determined to a large extent by the natureand characteristics of the fibers and weave pattern used to form saidlayers, as well as the forming process requirements.

[0020] Adhesive layer 40 can be applied so as to create aestheticdesigns or patterns that are visible through transparent layer 20.Moreover, adhesive layer 40 can be selectively applied so as to providesupport in specific areas of brassiere 10. A non-limiting example ofselective application of adhesive layer 40 provides support in the areaof brassiere 10 corresponding to the lower portion of the wearer'sbreasts. Adhesive layer 40 may further be applied to create both anaesthetic appearance in select portions of brassiere 10 and support inselect portions of brassiere 10. Alternatively, adhesive layer 40 can bevirtually transparent so that any designs or patterns provided onsupport layer 30 are visible through transparent layer 20 and theadhesive layer.

[0021] Referring again to FIG. 1, in a preferred embodiment of thepresent invention, brassiere 10 additionally has design aspectsrepresented by reference numeral 70. Design aspects 70 may be formed byor on any of transparent inner layer 20, outer support layer 30 oradhesive layer 40.

[0022] Having described some of the preferred characteristics of thepresent invention, the process for forming undergarment or brassiere 10,includes at least the following steps. First, fusing or adheringadhesive layer 40 to a surface of support layer 30, then cutting orshaping the fused adhesive-support layer into a desired shape,thereafter fusing or adhering the cut adhesive-support layer to asurface of transparent layer 20. Subsequently, forming breast supportingcup portions 50 of the undergarment, preferably by a subsequent moldingaction. The formed undergarment or brassiere 10 when worn has thesupport layer extending primarily under a wearer's breasts along thelower and side breast profile to provide an optimal balance of comfortand support, while the transparent layer provides the requisite sensualappeal.

[0023] The present invention having been thus described with particularreference to the preferred forms thereof, it will be obvious thatvarious changes and modifications may be made therein without departingfrom the spirit and scope of the present invention as defined herein.

What is claimed is:
 1. An undergarment, comprising: an inner transparentlayer having an inner and outer surface; an outer layer having an innerand outer surface; and a third, intermediate layer for adhering orfusing said inner layer and said outer layer, wherein the undergarmentprovides a balance of comfort, support and sensual appeal.
 2. Theundergarment of claim 1, wherein the undergarment is a brassiere.
 3. Theundergarment of claim 2, wherein said outer layer is a transparentmaterial.
 4. The undergarment of claim 3, wherein said transparentmaterial has sheer characteristics.
 5. The undergarment of claim 4,wherein said support material has firm resilient characteristics.
 6. Theundergarment of claim 2, wherein said outer layer is a support material.7. The undergarment of claim 2, wherein said third layer is an adhesiveor fusing material.
 8. The undergarment of claim 2, wherein said outerlayer is shaped to essentially extend under a wearer's breasts and alonga lower and side breast profile when the undergarment is worn.
 9. Anundergarment, comprising: a seamless transparent layer; a seamlesssupport layer; and an adhesive or fusing layer, wherein said adhesive orfusing layer securely adheres or fuses said seamless transparent layerto said seamless support layer, wherein the undergarment provides abalance of comfort, support and sensual appeal.
 10. The undergarment ofclaim 9, wherein the undergarment is a brassiere.
 11. The undergarmentof claim 10, wherein said seamless transparent layer is made of amaterial having sheer characteristics.
 12. The undergarment of claim 10,wherein said seamless support layer is made of a material havingresilient characteristics.
 13. The undergarment of claim 10, whereinsaid support layer is shaped to extend under a wearer's breasts alongthe lower and side breast profile to substantially support said breastswhen the undergarment is worn.
 14. A method for forming an undergarment,comprising the steps of: (a) providing a support layer; (b) applying anadhesive or fusing layer to said support layer; (c) cutting said supportlayer combined with said adhesive or fusing layer to a desired shape;(d) adhering or fusing said support layer with said adhesive or fusinglayer to a transparent layer to provide seamless connection; and (e)molding said support layer, said adhesive layer and said transparentlayer to form a unitary molded breast cup, wherein said support layerprovides reinforcing support along a lower profile portion of said cup,wherein the undergarment provides a balance of comfort, support andsensual appeal.
 15. The method of claim 14, wherein the undergarment isa brassiere.
 16. The method of claim 15, wherein said transparent layeris a material having sheer characteristics.
 17. The method of claim 15,wherein said support layer is a material having firm resilientcharacteristics.
 18. The method of claim 15, wherein said support layeris shaped so that when the undergarment is worn, said support layeressentially extends under a wearer's breasts and along the lower andside breast profile.